Leveler for solar module array

ABSTRACT

A leveler for a solar module can include a base, a rotatable adjuster, and a follower. The rotatable adjuster can be mounted to the base with a swaging process, or other techniques. The follower can be embedded within a coupler configured to be connectable to solar modules. Turning the rotatable height adjuster changes the relative spacing between the solar module and the base.

BACKGROUND OF THE INVENTIONS

1. Field of the Inventions

Embodiments of the subject matter described herein relate generally todevices and systems from mounting solar modules to fixed surfaces suchas roofs.

2. Description of the Related Art

Solar power has long been viewed as an important alternative energysource. To this end, substantial efforts and investments have been madeto develop and improve upon solar energy collection technology. Ofparticular interest are residential-, industrial- and commercial-typeapplications in which relatively significant amounts of solar energy canbe collected and utilized in supplementing or satisfying power needs.One way of implementing solar energy collection technology is byassembling an array of multiple solar modules.

One type of solar energy system is a solar photovoltaic system. Solarphotovoltaic systems (“photovoltaic systems”) can employ solar panelsmade of silicon or other materials (e.g., III-V cells such as GaAs) toconvert sunlight into electricity. Photovoltaic systems typicallyinclude a plurality of photovoltaic (PV) modules (or “solar tiles”)interconnected with wiring to one or more appropriate electricalcomponents (e.g., switches, inverters, junction boxes, etc.).

A typical conventional PV module includes a PV laminate or panel havingan assembly of crystalline or amorphous semiconductor devices (“PVcells”) electrically interconnected and encapsulated within aweather-proof barrier. One or more electrical conductors are housedinside the PV laminate through which the solar-generated current isconducted.

Regardless of an exact construction of the PV laminate, most PVapplications entail placing an array of solar modules at theinstallation site in a location where sunlight is readily present. Thisis especially true for residential, commercial or industrialapplications in which multiple solar modules are desirable forgenerating substantial amounts of energy, with the rooftop of thestructure providing a convenient surface at which the solar modules canbe placed.

As a point of reference, many commercial buildings have large, flatroofs that are inherently conducive to placement of a solar modulearray, and are the most efficient use of existing space. By contrast,many residential roofs may be sloped or angled such that placement of asolar module may be more difficult due to gravitational forces imposedon the angled modules. While rooftop installation is thus highlyvariable, it can be important to ensure that the array of solar modulesis reliably and stably anchored to the roof, whether the roof is anangled or flat roof. Moreover, it can be important to ensure that a usercan easily, effectively, and rapidly mount one or more solar module(s)to the roof.

SUMMARY

An aspect of at least one of the embodiments disclosed herein includesthe realization that certain known mounting systems for mounting solarmodules to fixed surfaces such as roofs include excessive componentsthat can be either reduced or eliminated and can require excessive laborfor removing and replacing modules. For example, one known solar modulemounting system is commercially available from Zep Solar. The Zep Solarsystem from mounting photovoltaic modules to a fixed surface such as aroof include three unique parts.

Firstly, the Zep Solar system includes splicing interlocks which areused to connect the frames of two adjacent modules together. A separateleveling foot is used only in locations where the leveling foot can beattached directly to frame of a module and where it is necessary toinclude a roof anchor. A third device known as a “hybrid interlock”,includes both splicing/interlock features for attaching two adjacentmodules to each other as well as a connection for anchoring the splicingdevice to the roof.

Other known solar module mounting systems include rails that areinitially mounted directly to a roof. The solar modules are then engagedwith the rails and then slid laterally into their final desiredlocation. Once in a desired location, the modules are fixed to therails.

Occasionally, a solar module that is surrounded by other solar modulesin an array, is damaged and thus requires replacement. Solar mountingsystems in which the solar modules must be slid along rails present asignificant difficulty when the need arises for replacing a solarmodule. In this situation, the rail-mounted array must be partiallydisassembled, i.e., the undamaged solar modules adjacent to the damagedmodule must be slid off of the rail first before the damaged module canbe removed. The replacement module is then slid along the rails backinto place. In a large array, this method of repair can require theremoval of many solar modules. Thus, a solar module mounting system thatcan allow individual solar modules to be removed from an array, withoutremoving adjacent modules can provide a significant labor savings.

The Zep Solar mounting system noted above, also suffers fromdifficulties. For example, the Zep Solar splice device includes arotatable fastener that extends and rotates about an axis that isgenerally horizontal. The rotatable fastener includes an engagement facefor engaging a tool that also must faces horizontally. Thus, in order toremove a solar module that is surrounded by other solar modules, aspecial tool is needed that includes a fastener engaging portion thatextends at a right angle. The tool must be inserted between two adjacentsolar modules and moved so that the engagement portion reaches theengagement face of the rotatable fastener. This procedure can beparticularly difficult when a worker is attempting to reach solar modulethat is surrounded by other modules, and thus in a position in which itis difficult to achieve the alignment of the special tool and theengagement face of the rotatable fastener.

Thus, in accordance with at least some embodiments disclosed herein, amounting system for mounting solar modules to a fixed structure such asa roof can be configured to allow solar modules to be removed from anarray of solar modules without the need to slide adjacent solar modulesoff of rails. Further benefits can be achieved by configuring a solarmodule mounting system such that the engagement portions of the mountingsystem can be removed by engaging upwardly facing fasteners.Additionally, further benefits can be achieved by configuring a solarmodule mounting system such that vertical adjustments can be made to themounting height of solar modules by engaging adjustment mechanism withan upwardly facing engagement portion.

In accordance with at least one embodiment, a height-adjustable roofanchor for solar modules can comprise a base having a hole therein, thehole comprising an inner wall. A height adjustment member can have anupper portion configured to engage at least one solar module, the heightadjustment member extending from the hole of the base and upwardly awayfrom the base, the height adjustment member having an annular grooveformed around the circumference of the rod, the annular groovepositioned within the hole. A locking portion can engage the annulargroove so as to retain the height adjustment member in the hole andallow the height adjustment member to rotate about a rotational axis,wherein the height adjustment member is configured to adjust a height ofthe at least one solar module during rotation about the rotational axis.

In another embodiment, a method can be provided for assembling aheight-adjustable roof anchor for solar modules which includes a basehaving a hole therein, the hole comprising an inner wall and a heightadjustment member having an annular groove formed around a circumferenceof the height adjustment member. The method can comprise inserting theheight adjustment member in the hole such that the annular groove ispositioned within the hole and positioning a locking portion so as toextend into the annular groove.

In accordance with another embodiment, a solar array can comprise aplurality of solar modules, each solar module having at least four sidesand a frame extending around the four sides of each solar module. Theplurality of braces supporting at least one side of one of the framescan be shorter than twice a length of one of the sides of one of theframes. Additionally, a plurality of roof anchors can be configured tobe mounted to a roof, each roof anchor coupled to one of the pluralityof braces.

In another embodiment, a method of assembling a solar array can comprisemounting a plurality of roof anchors to a roof. The method can alsoinclude coupling a brace to each roof anchor, positioning an edge of asolar module on each brace, and swinging the solar module downward toengage the end of the solar module with the brace.

In another embodiment, a kit for assembling a solar array can include aplurality of roof anchors configured to be coupled to a roof. The kitcan also include a plurality of braces, each brace configured to supportone or more frames of a solar module and configured to couple to one ofthe plurality of roof anchors, each brace being shorter than twice alength of a side of one of the frames.

In accordance with an embodiment, a solar array can comprise a pluralityof solar modules, each solar module having at least four sides andcomprising a solar module frame extending around at least a portion ofthe periphery of the solar module. At least a first brace member canhave a first support surface extending below at least a first solarmodule frame of the first solar module. At least a second brace membercan have a second support surface extending over the first solar moduleframe. A first connector can connect the first brace member to thesecond brace member such that the first solar module is captured betweenthe first and second support surfaces.

In accordance with another embodiment, a solar array can comprise atleast first, second, third, fourth, and fifth solar modules, each solarmodule having at least four sides, wherein the first, second, third, andfourth solar modules are respectively disposed adjacent to the foursides of the fifth solar module. Additionally, the array can includebraces for removal of the bracing the juxtaposed sides of the solarmodules to each other so that the fifth solar module can be disconnectedfrom the first, second, third, and fourth solar modules and liftedupwardly without the need to slide the fifth solar module laterally.

In accordance with another embodiment, a brace for connecting solarmodules can comprise a body member having first and second sides spacedfrom each other, a first lip extending outwardly from and along thefirst side of the body and configured to extend below a frame of a firstsolar module disposed adjacent to the first side and a second lipextending outwardly from and along a second side of the body andconfigured to extend below a frame to a second solar module disposedadjacent to the second side. The brace can also include at least a firsttop member configured to be connected to the body member and having afirst engagement portion extending outwardly from and along a first sideof the top member, the first engagement portion configured to engage inupwardly extending ridge of a first solar module frame, and a secondengagement portion extending outwardly from and along a second side ofthe top member, the second engagement portion configured to engage inupwardly extending ridge of a second solar module disposed adjacent tothe first solar module. A connector can be configured to connect thefirst top member to the body member so as to press the frames of the twoadjacent solar modules disposed along the first and second sides of thebody member between the lips of the body member and the engagementportions of the top member.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a perspective view of a solar power array including aplurality of solar modules.

FIG. 1B is a schematic diagram of an optional electrical system that canbe connected to the array of FIG. 1A.

FIG. 1C is an enlarged sectional view showing a typical cross section ofthe frame of each of the plurality of solar modules.

FIG. 2A is a perspective view of a first embodiment of a solar modulecoupler and a detachable height adjustment device.

FIG. 2B is an exploded view of the coupler and detachable heightadjustment device of FIG. 2A.

FIG. 2C is a bottom perspective, exploded view of the coupler of FIG.2B.

FIG. 2D is a side elevational view of the coupler and height adjustmentdevice of FIG. 2A connecting two solar modules to each other.

FIG. 2E is a side elevational view of the coupler connected to one solarmodule and a second solar module tilted relative to the coupler.

FIG. 2F is a side elevational view of the arrangement shown in FIG. 2E,with one solar module engaging a hook portion of the coupler and beingtilted into an engagement position.

FIG. 2G is a perspective view of the coupler of FIG. 2A connecting foursolar modules together at their corners.

FIG. 2H is a perspective view of an array of solar modules with onesolar module removed.

FIG. 3 is a perspective view of a second embodiment of the coupler ofFIG. 2A.

FIG. 4A is a perspective view of a third embodiment of the coupler ofFIG. 2A.

FIG. 4B is an exploded perspective view of the coupler of FIG. 4A.

DETAILED DESCRIPTION

The following detailed description is merely illustrative in nature andis not intended to limit the embodiments of the subject matter or theapplication and uses of such embodiments. As used herein, the word“exemplary” means “serving as an example, instance, or illustration.”Any implementation described herein as exemplary is not necessarily tobe construed as preferred or advantageous over other implementations.Furthermore, there is no intention to be bound by any expressed orimplied theory presented in the preceding technical field, background,brief summary or the following detailed description.

“Coupled”—The following description refers to elements or nodes orfeatures being “coupled” together. As used herein, unless expresslystated otherwise, “coupled” means that one element/node/feature isdirectly or indirectly joined to (or directly or indirectly communicateswith) another element/node/feature.

“Adjust”—Some elements, components, and/or features are described asbeing adjustable or adjusted. As used herein, unless expressly statedotherwise, “adjust” means to position, modify, alter, or dispose anelement or component or portion thereof as suitable to the circumstanceand embodiment. In certain cases, the element or component, or portionthereof, can remain in an unchanged position, state, and/or condition asa result of adjustment, if appropriate or desirable for the embodimentunder the circumstances. In some cases, the element or component can bealtered, changed, or modified to a new position, state, and/or conditionas a result of adjustment, if appropriate or desired

In addition, certain terminology may also be used in the followingdescription for the purpose of reference only, and thus are not intendedto be limiting. For example, terms such as “upper”, “lower”, “above”,and “below” refer to directions in the drawings to which reference ismade. Terms such as “front”, “back”, “rear”, and “side” describe theorientation and/or location of portions of the component within aconsistent but arbitrary frame of reference which is made clear byreference to the text and the associated drawings describing thecomponent under discussion. Such terminology may include the wordsspecifically mentioned above, derivatives thereof, and words of similarimport. Similarly, the terms “first”, “second”, and other such numericalterms referring to structures do not imply a sequence or order unlessclearly indicated by the context.

The inventions disclosed herein are often described in the context ofphotovoltaic arrays and modules. However, these inventions can be usedin other contexts as well, such as concentrated PV systems, thermalsolar systems, etc.

FIGS. 1A and 1B illustrate a solar power system 10 including a solararray 11 having a plurality of solar modules 12. Each solar module 12can include a laminate 14 supported by a frame 13. In some embodiments,the solar modules 12 can be the same as or similar to the modulesdisclosed in U.S. Patent Publication No. 2009/0320908, which isincorporated by reference herein in its entirety for all purposes.

With reference to FIG. 1B, the solar power system 10 can be incorporatedinto electrical system 40 connected to the array 11. For example, theelectrical system 40 can include the array 11 as a power sourceconnected to a remote connection device 42 with power lines 44. Theelectrical system 40 can also include a utility power source, a meter,an electrical panel with a main disconnect, a junction, electricalloads, and/or an inverter with the utility power source monitor. Theelectrical system 40 can be configured and can operate in accordancewith the descriptions set forth in U.S. Patent Publication No.2010/0071744, the entire contents of which are hereby expresslyincorporated by reference in its entirety for all purposes.

With continued reference to FIGS. 1A and 1C, each laminate 14 caninclude an array of solar cells, such as PV cells, configured to convertlight into electricity. The frame 13 can provide structural support forthe corresponding laminate 14 around the peripheral edges of thelaminate 14. In some embodiments, the frame 13 can be a separatecomponent that is coupled to the laminate 14.

The cross section of FIG. 1C illustrates the typical cross section ofthe peripheral members forming the frame 13. Each of the members formingthe frames 13 can be formed of longitudinally extending the framemembers, each having the cross section illustrated in FIG. 1C, andjoined at the corners using 45 degree cuts. However, other techniquescan also be used.

In the illustrated embodiment, the frame 13 includes a first outermember 16 which extends generally perpendicular to the laminate 14. Theouter member 16 includes an upwardly projecting ridge 18 and adownwardly projecting ridge 20. In the illustrated embodiment, the upperprotrusion 18 has a width W.

The outer member 16 includes an outwardly facing surface 22 whichgenerally forms the lateral, outwardly facing surface of the module 12.Projecting from the inner surface 24 of the outer member 16, the frame13 can include an upper sealing ledge 26 and a lower sealing ledge 28.The upper and lower ledges 26, 28 are spaced apart such that thelaminate 14 can fit therebetween. Optionally, various sealing techniquescan be used to seal the edge of the laminate 14 between the upper andlower ledges 28.

In the illustrated embodiment, the lower ledge 28 forms part of astiffening assembly 30 which also extends from the inner surface 24 ofthe outer member 16. The size and shape of the stiffening assembly 30can be chosen to provide the desired stiffness of the frame 13. In theillustrated embodiment, the stiffening assembly 30 includes arectangular tubular configuration. However, other shapes can also beused.

The frame 13, along with the components noted above, can be formed as astraight monolithic sections. For example, the frame pieces 13 can beextruded from aluminum, other metals or molded from plastic, or othermaterials. In some embodiments, the frame 13 is made from aluminum.Other configurations and dimensions can also be used.

With reference to FIG. 1A, the array 11 includes modules 12 mounted toeach other and, collectively, to a roof structure (not shown) with aplurality of brace assemblies 50. Some of the brace assemblies 50include optional height adjustment devices 52.

With reference to FIG. 2A, the brace assembly 50 can include a lowerportion 54 and an upper portion 56. The lower and upper portions 54, 56can be configured to capture a portion of the frames 13.

In some embodiments, the lower portion 54 can include a central bodyportion 56. In the illustrated embodiment, the central body portion 56is in the configuration of a box beam that extends in a generallylongitudinal direction. At a lower edge of the central body portion 56,the lower portion 54 can include a first lip 58 extending outwardly fromand along a lower edge of the main body portion 56.

Optionally, the lower portion 54 can include a second lip 60 extendingoutwardly from and generally along a lower edge of the central bodyportion 56 on a side opposite from the first lip 58. The first andsecond lips 58, 60 are sized and configured to support a portion of theframe 13.

For example, in some embodiments, the first and second lips 58, 60 aresized to support the lower ridge 20 (FIG. 1C) of two juxtaposed frames13. Optionally, in some embodiments, the first and second lips 58, 60include retention ridges 62, 64 that are sized and configured to helpretain the lower protrusion 20, for example, by providing for a snap-fitengagement of the frame 13. The engagement of the frame 13 with theridges 62, 64 is described in greater detail below with reference toFIGS. 2D-2F.

The upper portion 56 of the coupling member 50 can be formed in one ormore pieces. In the illustrated embodiment, the upper portion is formedfrom a first portion 70 and a second portion 72. The first and secondportions 70, 72 have essentially the same configuration and shape exceptthat they are mirror images of one another. Thus, only the first portion70 is described in detail below, with the understanding that theportions of the second portion 72 which are not expressly describedbelow, are essentially the same as the corresponding components of thefirst portion 70, except in a mirror image orientation.

With continued reference to FIGS. 2A and 2B, the first portion 70includes a central elongated portion 74 which extends generallongitudinally and parallel to the portion 56 of the lower portion 54.Optionally, a lower surface 76 can include ridges complimentary to theridges of the upper surface 65 of the lower portion 54. In theillustrated embodiment, the ridges on both the upper surface 65 and thelower surface 76 extend generally longitudinally along the couplingmember 50. As such, wherein at least one of the upper surface 65 and thelower surface 76 includes ridges, the engagement and electrical couplingbetween the upper portion 56 and the lower portion 54 is further ensuredthereby ensuring reliable electrical grounding between the upper portion56 and the lower portion 54. However, other configurations can also beused.

The first portion 74 also includes a first lip 80 extending outwardlyfrom and along an upper edge of the first portion 74 and a second lip 82extending outwardly from and generally along an upper edge of the firstportion 74. The first lip 80 is configured to cooperate with the firstlip 58 of the lower portion 54 to capture a portion of a frame 13 therebetween.

In the illustrated embodiment, the first and second lips 80, 82 aregenerally hook shaped, extending first, outwardly from the first portion74, then downwardly toward the lower portion 54. As such, the first andsecond lips 80, 82 can provide a further advantage in simplifying amethod for connecting a frame 13 to the coupling device 50, described ingreater detail below with reference to FIGS. 2D-2F.

The first portion 74 can also include notches 84, 86 in the first andsecond lips 80, 82, respectively. The notches 84, 86 can have a width 88that is at least as wide as the width W of the upper ridge 18 of theframe 13 (FIG. 1C). As such, the coupler 50 can be connected to a frame13 at a corner, wherein one part of the frame 16 extends perpendicularto the coupler 50, and another side where the frame extends parallel tothe coupler 50.

Optionally, the upper portion 56 can include centrally positionednotches 90, 92 on the first and second lips 80, 82. In the illustratedembodiment, the notches 90, 92 have a width 94 that is greater than thewidth 88.

In some embodiments, the width 94 can be about the same size as orgreater than a thickness 96 of the central portion 56 plus two times thewidth W of the upper ridge 18 (FIG. 1C). Sized as such, the notch 94 canallow more flexibility in the placement of the coupler 50, and inparticular, can allow the coupler 50 to be used in a position attachingthe corners of two modules 12 and straddling the corner. Thisarrangement is described in greater detail below with reference to FIG.2G.

With continued reference to FIG. 2B, each of the first and secondportions 80, 72 can be attached to the lower portion 54 in any knownmanner. In the illustrated embodiment, threaded fasteners 98 extendthrough apertures 100 to secure the first and second portion 70, 72 tothe lower portion 54.

Optionally, the upper portion 56 can include a height adjustmentaperture 102. In the illustrated embodiment, because the upper portion56 is formed of two portions 70, 72, each of the first and secondportions 70, 72 form approximately half of the aperture 102. However,other configurations can also be used.

The height adjustment aperture 102 can be size to accommodate theinsertion of a tool, from a position above the coupler 50, and down intothe interior of the coupler 50, to engage the height adjustment device52.

The height adjustment device 52 can include a base portion 110, arotatable height adjuster 112 which cooperates with a fixed threadedmember 114 which can be fixed to the coupler 50. The base portion 110can be formed in any configuration designed for a fixed connection to astructure such as a roof. In some embodiments, the base portion 110 canbe configured to be connectable to a roof stud, or other structuralmember, with a threaded fastener such as a lag screw or the like.

In the illustrated embodiment, the base portion includes a mountingplate portion 116 with an elongated slot 118. The elongated slot 118 ispreferably sized to receive an appropriately sized lag screw, designedfor the engagement of a roof structure and/or a roofing stud. The baseportion 110 can also include a receiver portion 120 for engagement withthe rotatable adjuster 112.

In the illustrated embodiment, the receiver portion 120 is generallyblock shaped with an upper aperture 122. The rotatable adjuster 112 caninclude a threaded body portion 130, an upwardly facing engagementsurface 132, and a neck portion 134. The neck portion 134 can be in theform of an annular groove disposed on the outer surface of the rotatableadjuster 112.

In some embodiments, the rotatable adjuster 112 can be swaged into theblock portion 120. For example, the rotatable adjuster 112 can beinserted through the aperture 122 into the block 120. Using anappropriate swaging technique, a portion of the block 120 can be pressedinwardly such that an inner wall of the aperture 122 extends into thenecked portion 134, thereby trapping the rotatable adjuster 112 withinthe block 120, but allowing the rotatable adjuster 112 to freely rotaterelative to the base 110. In some embodiments, the base portion and theblock portion 120 can be made from aluminum, the swaging of which iswell known in the art.

In the illustrated embodiment, the engagement surface 132 is in the formof a female allen wrench head. However, other engagement surfaces canalso be used.

With the rotatable adjuster 112 mounted as such, the threads of therotatable adjuster 112 can cooperate with internal threads on thecoupler 50, so as to allow the coupler 50 to be moved upward anddownwardly relative to the base 110. In some embodiments, as notedabove, an internal thread member 114 can be directly formed in the lowerportion 54.

With reference to FIG. 2C, the internal thread member 114 can extendthrough an aperture 140 extending through the lower portion 54.Optionally, the lower portion 54 can include an anti-rotation recess 142configured to cooperate with a portion of the internal thread member 114such that the thread member 114 can be fixed relative to lower portion54. In some embodiments, the internal threaded member 114 can include ananti-rotation aperture 144 configured to receive a fastener (not shown)extending through the aperture 144 and into the anti-rotation recess 142so as to prevent any relative rotation between threaded member 114 andthe lower portion 54. As such, when the rotatable adjuster 112 isrotated relative to the lower portion 54, and thus relative to theinternal thread member 114, the rotatable adjuster 112 operates as ajack screw, as the rotatable adjuster 112 is rotated clockwise orcounter clockwise. Other configurations can also be used.

In some embodiments, the threaded sleeve can also include a feature (notshown) that allows the threaded sleeve to be snapped into the base, butthat will prevent the threaded sleeve from being removedunintentionally, such as by wind forces. The feature can be aspring-loaded detent, barb formed in the sleeve, or any other suitablemechanism.

Optionally, with reference to FIG. 2C, the first and second lips 80, 82can optionally include one or more ridges, teeth, or spikes on thedistal end thereof. In the illustrated embodiment, the first and secondlips 80, 82 include a sharpened edge 130, 132 so that when they arepressed into engagement with a frame 13, the sharpened edges 130, 132penetrate the outermost surface of the frame 13, to thereby providebetter electrical contact with the frame 13. For example, in someembodiments, the frame 13 can be aluminum with a anodized outer coating.As such, the sharpened edges 130, 132 can help pierce the outermostanodizing of the frame 13, and thereby provide better electrical contactbetween the coupler 50 and the frame 13. Further, the sharpened edges130, 132 can also be further beneficial where the coupler 50 is madefrom a different material than the frame 13, for example, but withoutlimitation, where the coupler 50 is made from stainless steel and theframe 13 is made from aluminum.

With continued reference to Figures D, E and F, the above configurationcan accommodate two different methods for attaching coupler 50 to amodule 12. Firstly, as is apparent from the above description, the upperportion 56 of a coupler 50 can be removed, the frame of the module canbe placed such that the upper ridge 18 of a frame engages the hookshaped lip 80 with the lower protrusion 20 of the frame supported by thelower lip 58. The upper portion 56 can be secured to the lower portion54 of the coupler with the threaded fasteners 98.

Additionally, the above configuration of the coupler also allows amodule 12 to be connected to the coupler 50 by a “hook and swingmotion.” For example, as shown in FIG. 2D, the coupler is fullyassembled with the upper portion 56 attached to the lower portion 54. Asolar module 12A is illustrated in the position in which it is tiltedrelative to coupler 50. The module 12A can be manually moved into aposition in which the upper protrusion 18 is engaged with the hookshaped lip 82. Then, the module 12A can be tilted downwardly, in thedirection of arrow T until the module 12A reaches the orientationillustrated in FIG. 2F.

As noted above, the lip 60 can include a ridge 64 configured tocooperate with the lower protrusion 20 of the frame 13 so as to providea snap fit. Those of ordinary skill in the art fully understand how tosize and configure the lips 60, 82 and the ridge 64 to provide such asnap fit.

For example, the minimum distance between the uppermost portion of theridge 64 and the uppermost portion of the inner surface of the hookshaped lip 82 can be slightly closer than the overall vertical Height ofthe outer portion 16 of the frame 13. As such, as the module 12A istilted in the direction indicated in FIG. 2E, and the lower protrusion20 reaches the ridge 64, the inherent elasticity of the coupler 50 andin particular the hook shaped lip 82 and the lip 60 can allow the lips82, 60 to slightly spread apart as the lower protrusion 20 passes overthe ridge 64, then due to their elasticity, snap back to their originalspacing, thereby trapping the outer member 16 of the frame 13 in theposition illustrated in FIG. 2F. Similarly, the lips 58, 80 and ridge 62can be configured in essentially the same manner such that solar modules12, 12A can be attached to both sides of the coupler 50 without the needfor moving the lips 80, 82 relative to the lower lips 58, 60.

With continued reference to FIG. 2F, where a coupler 50 is used toconnect two adjacent solar modules 12, 12A, the solar modules 12, 12Aare spaced apart such that the inwardly facing surfaces of theirrespective upper ridges 18 as defined by the width 200. The width 200,in the illustrated configuration, is approximately the width 96 of thecentral portion of the coupler 50 plus two times the width W of theouter portion 16 of the frames 13. This spacing is about the same as orless than the width 94 of the notch 92 (FIG. 2A) described above.

More particularly, with reference to FIG. 2G, when a coupler 50 is usedto connect two or more modules at a corner, the width 94 of the notch 92allows the notch 92 to straddle the spaced apart upper ridges 18 of twoadjacent modules 12. Note that the laminates 14 of the solar modulesillustrated in FIG. 2G have been removed for purposes of illustration.Additionally, as also noted above, the width 88 of the notches 86 alsoallow the coupler 50 to be positioned near a corner of a module 12, butnot straddling the spacing between two adjacent modules 12. Rather, thenotches 86 could be aligned with single upper ridge 18 of a frame 13.

With reference to FIG. 2H, the couplers 50 can accommodate furtheradvantageous methods for removing and reinstalling a solar module 12from an array of solar modules. As shown in FIG. 2H, the upper portions56 of two couplers 50 have been removed and the module 12 (FIG. 1A) hasbeen removed by lifting and tilting the module 12 out of the fullyassembled couplers 50B.

In order to reinstall another solar module into the original placementof the solar module 12, one edge of the solar module 12 can be loweredinto position, into the orientation illustrated in FIG. 2E, such that inupper protrusion 18 of the frame 13 of the solar module 12 engages thehook shaped lip 82 of the couplers 50B. As the module 12 is tilted intoplace, the lower protrusion 20 can engage with the ridge 64 of thecouplers 50B. Similarly, on the opposite edge of the module 12, thelower protrusion 20 eventually comes to rest on the first lip 58 of thecouplers 50A. The lowering of the solar module 12 can be accomplishedusing suction cups (not shown) temporarily attached to the upper surfaceof the laminate 14, or other techniques. After the module 12A has beenlowered into position, the upper portions 56 of the couplers 50A can bereplaced, thereby returning the array 11 into the state illustrated inFIG. 1A.

Further, when installing and/or servicing the array 11, all of thecouplers, 50, 50A, 50B, which are attached to height adjustmentmechanisms, can all be adjusted to desired heights by inserting,directly from above, an engagement tool configured to engage theengagement surface 132 (FIG. 2B) of the rotatable height adjuster 112 soas to raise or lower each of the modules 12, to the desired height. Assuch, the heights of the various modules 12 of the array 12 can beeasily adjusted.

FIG. 3 illustrates another embodiment of the coupler 50, identified bythe reference numeral 1050. The components of the coupler 1050 that arethe same or similar to the coupler 50, are identified with the samereference numeral, except that 1000 has been added thereto.

As shown in FIG. 3, the coupler 1050 can include an upper portion 1056that is made from a single piece instead of two separate pieces 70, 72of the coupler 50. The remaining components of the coupler 1050 as wellas the use and operation, are essentially the same as the coupler 50.

In yet another alternative embodiment, the coupler 1050 can be formedsuch that the upper portion 1056 is permanently affixed to the lowerportion 1054. For example, the coupler 1050 could be made from a singlepiece of material into a monolific body. Alternatively, the coupler 1050could be made from two separate pieces such as the lower and upperportions 1054, 1056, but permanently affixed to one another.

Such an integrated design for the coupler 1050 can further reduce costsof such a system, by reducing the part counts, and reduce manufacturingcosts. In use, such as single piece coupler 1050 can be connected to afixed solar module by hooking the lip 1080 to an upper ridge 18 of asolar module 12, then tilting the coupler 1050 relative to the solarmodule 12, until the lower protrusion 20 of the frame 13 of the solarmodule engages the ridge 1062. Then, with the coupler 1050 fit onto onesolar module 12, an adjacent solar module 12 can be connected to thecoupler 1050 by hooking the corresponding upper protrusion 18 of a solarmodule 12 into the hook shaped lip 1082 of the coupler 1050, thentilting the solar module 12 downwardly, in the direction of RT of FIG.2E, until the lower protrusion 20 engages the ridge 64 and is orientedin the position shown in FIG. 2F. As such, such a single piece coupler1050 can be used without removing the upper portion 156.

FIG. 4A illustrates another embodiment of the coupler 50, identified bythe reference numeral 2050. The components of the coupler 2050 that arethe same or similar to the couplers 50 or 2050 are identified with thesame reference numeral, except that 2000 has been added thereto.

With reference to FIGS. 4A and 4B, the coupler 2050 can include a lowerportion 2054 and an upper portion 2056. In the illustrated embodiment,the lower portion 2054 includes the lip 82 and an upper mounting surface2402 for receiving the upper portion 2056. Additionally, similarly tothe embodiments of FIGS. 2B and 3, the upper portion 2056 can be madefrom one or more parts.

The upper portion 2056 can include a lip only on one side, in theillustrated embodiment, the lip 2080. The coupler 2050 can be engagedwith a solar module 12 by hooking and tilting the coupler relative tosolar module 12 as described above with reference to FIG. 3.Additionally, the coupler 2050 can be connected to and removed fromengagement with solar modules by removing the fasteners 98 and the upperportion 2056. As such, the upper portion 2056 can be removed while theother side of the coupler 2050, including the upper lip 82 can remainengaged with a solar module, thereby maintaining the coupler 2050 in itsposition.

This can provide a further advantage when using the coupler 2050 in anarray 11, and in particular, when removing and reinstalling the solarmodule from an array in which the solar module is surrounded by othermodules. Thus, when the upper portion 2056 is removed, so as to allow asolar module to be removed from the array, the coupler 2050 can remainsecurely engaged with an adjacent solar module because the lip 2082remains fixed relative to the lower lip 2060. Thus, the solar module 12which is removed and/or reinstalled can rest against the lower lips 2058of the coupler 2050, during the reinstallation process.

While at least one exemplary embodiment has been presented in theforegoing detailed description, it should be appreciated that a vastnumber of variations exist. It should also be appreciated that theexemplary embodiment or embodiments described herein are not intended tolimit the scope, applicability, or configuration of the claimed subjectmatter in any way. Rather, the foregoing detailed description willprovide those skilled in the art with a convenient road map forimplementing the described embodiment or embodiments. It should beunderstood that various changes can be made in the function andarrangement of elements without departing from the scope defined by theclaims, which includes known equivalents and foreseeable equivalents atthe time of filing this patent application.

What is claimed is:
 1. A height-adjustable roof anchor for solarmodules, the roof anchor comprising: a base having a hole therein, thehole comprising an inner wall; a height adjustment member having anupper portion configured to engage at least one solar module with abrace, the height adjustment member extending from the hole of the baseand upwardly away from the base, the height adjustment member having anannular groove formed around the circumference of the rod, the annulargroove positioned within the hole; a locking portion engaging theannular groove so as to retain the height adjustment member in the holeand allow the height adjustment member to rotate about a rotationalaxis, wherein the height adjustment member is configured to adjust aheight of the at least one solar module during rotation about therotational axis; a sleeve disposed over the height adjustment member andconfigured to be disposed through an opening in the brace; and ananti-rotation portion to prevent relative rotation between the sleeveand the brace.
 2. The roof anchor of claim 1, wherein the heightadjustment member comprises a rod with a threaded portion and anon-threaded portion, the annular groove formed in the non-threadedportion.
 3. The roof anchor of claim 2, wherein the threaded portion ofthe rod extends out of the hole, and wherein at least part of thenon-threaded portion is positioned within the hole.
 4. The roof anchorof claim 3, the non-threaded portion comprising a plurality of annulargrooves formed around the circumference of the rod and the inner wallcomprising a plurality of locking portions, each locking portionextending into a corresponding annular groove.
 5. The roof anchor ofclaim 1, wherein the locking portion of the inner wall is swaged intothe annular groove.
 6. The roof anchor of claim 1, wherein the lockingportion of the inner wall is configured to substantially prevent theheight adjustment member from being removed from the hole.
 7. The roofanchor of claim 6, wherein the locking portion of the inner wall isconfigured to allow rotation of the height adjustment member about alongitudinal axis of the height adjustment member.
 8. The roof anchor ofclaim 1, wherein the base comprises a mount configured to mechanicallycouple to a roof and an extruded foot, the hole being formed in theextruded foot.
 9. The roof anchor of claim 8, wherein the base is madeof aluminum and the height adjustment member is made of steel rod. 10.The roof anchor of claim 8, the mount comprising a slot configured toreceive a coupling member for securing the roof anchor to the roof. 11.The roof anchor of claim 1, wherein the sleeve is threaded over athreaded portion of the height adjustment member.
 12. The roof anchor ofclaim 11, wherein the sleeve is configured to positively locate thebrace relative to the sleeve, and wherein the sleeve is configured to beremoved when a detent or latching mechanism is engaged.